WO1998045546A1

WO1998045546A1 - Porous building materials and method of manufacturing same

Info

Publication number: WO1998045546A1
Application number: PCT/US1998/006909
Authority: WO
Inventors: Miroslav Vitous
Original assignee: Miroslav Vitous
Priority date: 1997-04-09
Filing date: 1998-04-08
Publication date: 1998-10-15
Also published as: AU6889098A

Abstract

A building panel (10) is formed using particulate material (16), such as sand, with an adhesive binder, to form an aggregate. The mix undergoes a heating process to cure the adhesive, which also produces a porosity in the panel. The relative quantities of the materials are such that the resulting panel (10) is porous after heating, with the interstices (18) between particles (16) being devoid of binder material. The resulting porosity provides for the limited passage of air and moisture, particularly water vapor, through the panels (10) so the panels (10) may 'breathe' to allow circulation through a structure (S) composed of the present panels (10), and also provides acoustic properties.

Description

POROUS BUILDING MATERIALS AND METHOD OF MANUFACTURING SAME

BACKGROUND OF THE INVENTION

1. FIELD OF THE INVENTION

The present invention relates generally to building materials formed of cured fluid aggregates, and more specifically to building structural components and panels formed of a coarse sand material suspended in an adhesive resin matrix. The sand and adhesive mix may be poured in place to form a structural slab after curing, or may be formed as precast panels which may be assembled to form a completed structure after curing and hardening. Curing is accelerated by an optional heating process, but the material will cure and harden in ambient temperatures over a relatively longer period of time. The slabs and panels of the present invention are formed to have a porosity, through which air, water vapor, and liquid water may pass. The slabs and panels are useful for both interior and exterior construction, as the porosity greatly impedes, but does not completely preclude, the flow of fluids and gases therethrough.

2. DESCRIPTION OF THE RELATED ART

The advance of technology has permitted newer materials, and older known materials used in different ways and combinations, to be used in the construction of building panels and other prefabricated components. Generally, it has been considered desirable to provide better insulation, sealing, durability, and fire and weather protection in the building construction field, and as a result the materials which have been developed have tended to provide such features or qualities, including having a relatively impervious nature to preclude the passage of the elements therethrough.

However, such imperviousness is not always desirable, as evidenced by screens, open decorative block, and other structural and non-structural building materials and panels. Depending upon the climate, it may be desirable in some areas to provide solid, opaque building materials which provide most of the benefits of such materials (non-flammability, durability, acoustic insulation, etc.) while still providing at least limited porosity for air and/or moisture circulation. Accordingly, the present invention provides such materials in various embodiments thereof, for use in the building trade where applicable. A discussion of the related art known to the present inventor, and its differences from the present invention, is provided below.

U. S. Patent No. 2,340,535 issued on February 1, 1944 to Paul W. Jenkins describes Building Material of expanded vermiculite (a hydrated silicate mineral) and gypsum (a hydrated calcium sulphate used in the manufacture of plaster, etc.) . These materials are subject to dehydration when exposed to extreme heat (as in a fire) , which leads to their shrinking, cracking, and losing strength. Jenkins combines the two materials to avoid such cracking (which cracks by definition produce a porous material) . Thus, Jenkins teaches away from the present invention, with its deliberately porous nature and the optional heating process used in the manufacture of the present materials. In any event, the materials used by Jenkins are dissimilar to those used in the present invention with its coarse sand material and adhesive binder. U. S. Patent No. 2,791,020 issued on May 7, 1957 to Henry W. Heine describes a Method Of Making Composite Fireproof Acoustical Tile, wherein the ceramic material is mixed with a carbonaceous material which is then burned out during the baking process to leave a porous ceramic material . The glaze is accomplished in a similar manner. The present invention may also use a heating process during manufacture, but the heat assists in the cure of the adhesive used to bind the sand grains together with voids therebetween to provide a porous panel. The materials of the present invention also inherently include acoustic properties, but may also have such acoustic materials added to a specially formed panel in addition to the acoustic properties of the panels or other materials themselves, if desired.

U. S. Patent No. 2,825,420 issued on March 4, 1958 to Henry W. Heine describes Acoustical Tile And Method Of Manufacturing It, wherein a clay base is mixed with a large quantity of water and carbonaceous material before baking or firing. The process is similar to that described immediately above in the '020 patent to the same inventor, but including the addition of water to the material to produce steam during firing. U. S. Patent No. 3,182,747 issued on May 11, 1965 to Hans Wilhelmi et al . describes Sound Absorbing Micro-Porous Wall Panel Structures. The panels are formed by mixing a fast evaporating solvent with a curing material. The evaporation of the solvent leaves interconnected voids in the material. The resulting panels are relatively thin and flexible, and do not contain minerals such as sand, as in the present poured in place slabs and prefabricated panels .

U. S. Patent No. 3,204,380 issued on September 7, 1965 to Burton F. B. Smith et al . describes Acoustical Tiles With Thermoplastic Covering Sheets And Interlocking Tongue-And-Groove Edge Connections. The tiles are formed of fibrous materials in a binding agent, rather than using quartz sand as used in a preferred embodiment of the present invention. Smith et al . overlay the panels with a non-porous plastic sheet or film bonded along the common peripheries of the tile and sheet. Such an impervious sheet teaches away from the present porous material and panel invention.

U. S. Patent No. 4,611,445 issued on September 16, 1986 to James 0. Pressley describes a Sag-Resistant Ceiling Panel formed of mineral wool (glass fiber, etc.) treated with lithium carbonate. The lithium carbonate treatment delays the devitrification and crystallization of the fibers at high temperatures, so such a panel will possess greater strength to resist sagging and falling in the event of a fire. Panels formed using the building material of the present invention may be used as ceiling panels, but, as the panels themselves are not formed of fiber material (as opposed to any acoustic insert which may be added to the panels) , the lithium carbonate treatment of Pressley is not applicable to the present panels.

U. S. Patent No. 4,815,243 issued on March 28, 1989 to Jorge Pardo describes Concrete Masonry Block And Stud Wall Construction Systems, comprising specially formed solid concrete blocks adapted for placement in interior walls. No porosity is disclosed, nor are the blocks formed of sand with an adhesive binder, as in the present invention.

Japanese Patent Publication No. 6-42071 published on February 15, 1994 relates to the addition of a water repellant agent to porous ceramic acoustic material, to improve the acoustic properties of the material if it becomes wet or damp. The present panels include acoustic properties, but no substantial degradation of those properties occurs when the panels become wet, due to the water impervious adhesive and mineral materials used. The present panels may also incorporate additional acoustic means if desired. French Patent Publication No. 2,704,015 published on October 21, 1994 to Jurg Scheiwiller relates to a composite acoustic panel having a fibrous acoustic material completely captured within a hollow acoustic mortar panel, and including a metal reinforcing screen therein. The mortar panel may be formed of sand and a synthetic resin, as in panels formed using the materials of the present invention, but no disclosure is made regarding any structural features lending porosity to the mortar panel, or a method of forming such porous features, as provided in the present building material.

Finally, World Patent Publication No. 94/24381 published on October 27, 1994 to Jurg Scheiwiller relates to a sound absorbent material. This publication is related to the '015 French patent publication to the same inventor, and discussed immediately above. The same differences and distinctions apply here as those described above in the discussion of the '015 French patent publication.

None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.

SUMMARY OF THE INVENTION The present invention comprises a building material formed by mixing a particulate mineral, such as sand, with a viscous adhesive matrix binder, such as an epoxy resin. The material may be poured in place to form a continuous slab when the adhesive binder is still in an uncured fluid state, with the adhesive material curing and hardening by exposure to ambient temperatures over a period of time. The mix may also be used to form individual precast panels, which may then be transported to the building site and used in the construction of the building structure. Both panels and continuous slab embodiments may also be more rapidly cured by heating. The slabs and panels of the present invention are homogeneous in construction and include acoustic properties, but additional acoustic material may be added thereto if desired. A novel feature of the cured material is its porosity, achieved during the curing process as the adhesive hardens. The particulate base material may be colored by mixing with a dye, paint, or other suitable agent prior to mixing with the adhesive to produce colored panels or slabs, if desired. The materials used are non-flammable.

Accordingly, it is a principal object of the invention to provide an improved building panel formed predominantly of a particulate mineral such as a coarse, rough sand, using an adhesive binder to form an aggregate.

It is another object of the invention to provide an improved building panel which is porous to allow air and moisture passage therethrough .

It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.

These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is an environmental perspective view of a building structure incorporating a plurality of the present panels to form an exterior wall.

Figure 2 is a perspective view of a single panel of the present invention.

Figure 3 is a side elevation view in section of a portion of one of the present panels, showing the pervious nature of the panel structure.

Figure 4 is a perspective view in section of an alternative embodiment of the present panel invention, showing a cavity formed in one side thereof with the cavity being filled with a sound absorbent material . Figure 5 is a flow chart disclosing the basic steps in a first method of manufacturing the present building panels .

Figure 6 is an environmental perspective view of the present building material being poured in place within a form at a construction site, to form a hardened slab when cured. Figure 7 is a flow chart disclosing the basic steps in a second method of manufacturing the present building slabs or panels .

Similar reference characters denote corresponding features consistently throughout the attached drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention comprises a porous, non-flammable building panel 10 which may be used for interior and exterior construction of walls and ceilings, as desired. An exemplary structure S is shown in Figure 1, with a panel frame F holding a plurality of such panels 10 in a rigid wall structure. (It will be understood that such panels 10 may be formed in any practicable size and shape, and are not limited to the substantially wide and flat, square configuration shown in the various drawing figures.)

The present panels 10 are particularly well suited for use in relatively mild environments as exterior wall panels, with the porosity of the panels 10 allowing some movement and circulation of air and water vapor therethrough (and limited flow of liquid water therethrough, if exposed to a standing head of water for a sufficient time) . Thus, the panels 10 may be considered to "breathe" to allow circulation through the structure S. The porous nature of the panels 10 also provides a myriad of air cavities to break up sound transmission therethrough, thus providing acoustic properties in addition to the "breathable" nature of the panels 10.

Figure 2 provides a view of a single panel 10. The panels 10 of the present invention are formed using a non-flammable granular particulate mineral in a matrix or binder of adhesive material. It has been found that a quartz sand having relatively rough and coarse grains works well, in that the roughness of the grains provides a good "tooth" to which the adhesive material may adhere, with a relatively coarse texture accounting for a part of the creation of the required interstitial spaces between individual grains for the desired porosity during the manufacturing process, even after the particulate matter has been bound together by the adhesive .

The adhesive material is preferably a synthetic resin of a suitable type, i. e., one that does not break down when exposed to moisture, ultraviolet light (sunlight), etc. An epoxy resin has been found to have suitable properties, although other resins, such as polyesters, may be substituted where suitable.

The panels 10 of the present disclosure are shown with beveled edges 12 about the periphery of the first surface 14 thereof, for ease of fastening such aggregate panels 10 into a frame F. However, other configurations may be used, and the panels may be adhesively or mechanically secured in place (bolts, etc.), as desired. Figure 3 provides a side elevation view in section of one of the present panels 10. It will be seen that the panel 10 is predominantly formed of a multitude of individual particulate grains 16, which are adhered together by relatively small amounts of adhesive material between adjacent grains. (It will be understood that the granular size may be exaggerated in the drawing figure, and that irregular, roughened grains may be preferred. )

The panels 10 of the present invention may be formed of any practicable size and thickness. It has been found that the present panels 10 may be formed as wide and flat units having a thickness 21 defined between their first surfaces 14 and opposite second surfaces 20, of between three and forty millimeters, or approximately one eighth of an inch to two inches. The relatively thin and lightweight panels are excellent for use as ceiling panels, due to their light weight and structural rigidity provided by the materials used in their formation. The present panels 10 may be formed in any practicable shape, with their shapes not being limited to the rectangular shape of the panel 10 shown in Figure 2. Preferably, such panels 10 are formed as relatively wide and flat units, having a major lateral dimension 25 ranging from as little as one quarter of an inch (for use as relatively small tiles) up to eight feet or more (for use as wall or ceiling panels) , with the panels 10 having larger lateral dimensions preferably also having a relatively greater thickness if they are to be used in unsupported areas. However, the relative lateral dimensions and thicknesses may be varied to suit specific installation needs, as desired.

Other configurations may be formed, as shown in Figure 4. The panel 10a of Figure 4 includes a first surface 14a, analogous to the first surface of panel 10. However, the opposite second surface 20a will be seen to be inset within the second surface periphery 26 of the panel 10a, thus defining a cavity or depression 28 contained within the second surface periphery 26. This depression 28 may be used to contain insulating materials of various sorts, such as the acoustic insulation material 30 ("sound proofing") shown in Figure 4. In keeping with the intended environment of use of the present panels 10 and 10a, the acoustic material 30 is preferably a porous non-flammable material, such as a glass fiber roving or mat, etc. Various mineral wools and other non-flammable acoustic materials may be placed within the depression or cavity as desired, to substantially fill the depression 28. It will be understood that the porous nature of the present panels, with their myriad interstitial air spaces therein, provide fairly good acoustic attenuation without need for further acoustic panels installed thereto. However, the embodiment of Figure 4 provides for such if so desired.

It is anticipated that the present building panels 10 and 10a will be exposed, at least on their first surfaces 14 and 14a, rather than being concealed, which would tend to negate the effect of the porosity of the panels 10 and 10a. Accordingly, the panels 10 and 10a may be colored or tinted as desired at the time of manufacture, by adding a coloring agent to the particulate matter and allowing it to cure before mixing the adhesive binder with the particulate matter. This mixing of the coloring agent with the particulate material and adhesive will result in each of the grains of material being substantially coated by the coloring agent prior to the heating process, with the panels 10 and 10a taking on the color of the coloring agent used in the formation of the panels 10 and 10a, whatever that color may be.

In a first embodiment of manufacturing the building component, the component are precast in molds and transported to a construction site as prefabricated panels for use in the construction of interior and exterior walls and ceilings due to their rigidity and light weight when cured, particularly in their thinner embodiments, as shown in Figure 2. In this embodiment of manufacturing, the building components 10 are formed by mixing a suitable quantity of the particulate material (sand, etc.) with an appropriate quantity of the adhesive (resin) and forming the mix into a suitable shape. The mix of particulate material and adhesive binder is then heated under specific conditions to harden and cure the adhesive binder to form a rigid aggregate, an example of which is shown in Figure 2. The specific heating process, in combination with the specific materials used, also creates the porosity in the panels.

Preferably, the quantity of adhesive binder used is relatively small in comparison to the quantity of particulate matter used in the formation of the present panels 10. While the above noted specific heating process assists in creating the porous nature of the completed panels 10, it will be seen that the inclusion of too much adhesive binder will result in the interstices between particles being filled to a certain extent and at least partially blocking the gaps and voids otherwise formed throughout the completed aggregate. A mix of about 90 percent particulate matter and about 10 percent adhesive has been found to work well, but other ratios may be used according to the desired result . By thoroughly mixing the relatively small amount of adhesive

(resin, etc.) with the relatively large amount of granular material, each of the grains becomes substantially coated with the adhesive and will adhere on contact to an adjacent grain. It will be seen that a relatively thin coating of adhesive on the grains, as opposed to immersion in a larger quantity of the adhesive material, will result in a myriad of interstices 18 between the multitude of particulate grains 16.

When the adhesive has hardened and cured during the heating process, these interstitial spaces 18 result in a porosity which allows air or other gaseous vapor to flow through the aggregate panel 10 from the first surface 14 to the opposite second surface 20, as indicated by the inward flow arrow 22, or to flow equally as well through the panel 10 from the second surface 20 and out through the first surface 14, as indicated by the outward flow arrow 24. The resulting aggregate panel 10 is a solid, substantially homogeneous mass having essentially a uniform thickness defined by the first and second surfaces 14 and 20.

Figure 5 is a block diagram disclosing the basic steps in the manufacture of the present panels 10 and 10a by the first manufacturing embodiment. In the first step 32, the particulate matter (e. g., coarse sand) and adhesive binder are mixed in suitable proportions, with the particulate matter accounting for the majority of the mass of the mixture. The particulate and adhesive mixture is then heated in accordance with a specific process to cure the adhesive binder, as indicated in the second step 34 of Figure 5. If it is desired that the completed panels be colored or tinted in some way, a coloring agent (epoxy paint, or other suitable coloring agent or material as desired) may first be added to the particulate matter and allowed to cure, then mixed with the adhesive binder and heated, as indicated in the optional third step 36 of Figure 5.

In a second manufacturing embodiment the building component may be poured in place as a continuous slab, as shown in Figure 6. Figure 6 illustrates the pouring of the viscous liquid mix from which the present building materials are formed, to form a continuous slab 100 once the aggregate mix has cured and hardened. The thickness 120 of the slab 100 (indicated generally by the height of the forms F) may vary between three millimeters (or approximately one eighth of an inch) and fifty centimeters (or approximately twenty inches) . The present material forms a rigid and hard aggregate when cured, and additional reinforcement is not required in many, if not most, circumstances. However, additional reinforcement, and/or conduits for electrical wiring and plumbing, etc., may be included in thicker slabs 10 as desired before they are poured and are cured and harden.

The slab 100 of Figure 6 will have much the same properties as the panel 10 of Figure 1. This can be most desirable and useful in certain circumstances, where such a slab 100 is formed out of doors (e. g., sidewalks, driveways, decks, etc.), where good drainage is provided therebeneath. Such slabs 100 formed outdoors over good drainage will allow liquid (rain, water runoff, etc.) to pass through the porous material, thereby providing rapid drying of the upper surface of the slab. This is also most advantageous in freezing rain, or where water may collect and later freeze, as the porosity of the slab 100 allows the liquid water to pass through the slab 100 before it has an opportunity to freeze, thus precluding a buildup or coating of slippery ice on the surface of the slab 100 under such conditions. In many instances, it may not be desirable for such a slab 100, when poured in place as a floor and foundation, to have such porous properties. This is easily remedied by applying a moisture proof vapor barrier (plastic sheet, etc.) to the area where the material is to be poured before it is poured. The resulting slab 100, when cured and hardened, provides all the required durability of a conventional concrete slab, including the moisture impervious nature of such material. The moisture proof barrier may be omitted, if not required. The present slabs 100 and panels 10 are formed by mixing a suitable quantity of the particulate material (sand, etc.) with an appropriate quantity of the adhesive (resin) and forming the mix into a suitable shape. The mix of particulate material and adhesive binder is then allowed to cure under specific conditions and time to harden and cure the adhesive binder to form a rigid aggregate, an example of which is shown in Figures 2 and 3. The specific curing process, in combination with the specific materials used, also creates the porosity in the cured slab 100 and panels 10. The curing and hardening process may comprise one of two different procedures. It has been found that the present materials will cure and harden satisfactorily when exposed to ambient temperatures (i. e., 60 to 100 deg. Fahrenheit, with temperatures outside that range modifying the time period required for curing somewhat) . With relatively thin slabs 100 and panels 10, exposure to such temperatures for a period on the order of thirty six hours or so suffices, while the curing and hardening process in ambient temperatures may extend for up to two weeks for thicker slabs 100. This curing and hardening process may be accelerated greatly by applying heat to the uncured and viscous aggregate mix, with the heat accelerating the chemical reaction taking place within the epoxy resin adhesive binder. The application of heat reduces the time required for curing and hardening by a considerable amount. It will be seen that even a poured in place slab 100 may be cured and hardened by heating, as by using space heaters, heat guns, or even piping hot water or air through conduits captured therein.

Figure 7 is a block diagram disclosing the basic steps in the manufacture of the slabs 100 and panels 10. If it is desired that the completed slabs 100 and panels 10 be colored in some way, then a coloring agent (epoxy paint, or other suitable coloring agent or material as desired) may first be added to the particulate matter and allowed to dry or cure. This coloring or tinting of the panels by coloring the particulate grains is optional and is not required for the structural strength and durability of the completed slabs 100 and panels 10, but adds an attractive and decorative appearance to the materials. Again, this coloring extends throughout the entire slab 100 or panel 10, as it is achieved by coating each of the particulate grains, which grains are mixed essentially homogeneously throughout each of the panels 10 and slabs 100 formed according to the present invention. This optional first step is designated with the reference numeral 340 in Figure 7, and is shown related to the next step by a broken line.

The colored or uncolored particulate matter (e. g. , coarse sand) and uncured, viscous adhesive binder are then mixed in suit-able proportions, with the particulate matter accounting for the majority of the mass of the mixture. A mix by volume of about 90 percent particulate matter and about 10 percent adhesive has been found to work well, but other ratios may be used according to the desired result. The same ratios are applicable to both slab 100 and panel 10 formation, regardless of the size and thickness of the panels or slabs. This second step is indicated using the reference numeral 360 in Figure 7.

In the third step 380 of Figure 7, the viscous mixture of particulate grains and uncured adhesive binder are poured in to suitable forms or molds to cure in the desired slab or panel final configuration, according to the shape and size of the form or mold and the volume of the viscous mixture poured therein. If a slab

100 is being formed, the required form may be constructed on site, as shown in Figure 6, with the uncured mixture being poured directly therein. Smaller, more portable panels used for wall and ceiling panels and tiles, (or even as floor tiles) , as shown in Figure 2, may be precast before use in individual molds or forms and allowed to cure and harden before transport to the construction site for assembly into the building structure.

As noted further above, the present mixture of materials used to form the slabs or panels of the present invention will cure and harden in ambient temperatures, given sufficient time. The time required is dependent upon the temperature as well as the thickness of the poured mixture, and may range from several hours (e. g., thirty six hours or so) up to several days (e. g., two weeks or so) , with thicker panels or slabs and cooler ambient temperatures requiring greater amounts of time to cure and harden. This step of curing and hardening the present panels and slabs in ambient temperatures, is shown in the step designated by the reference numeral 400 in Figure 7. The particulate and adhesive mixture used to form the present panels and slabs will cure and harden more rapidly if exposed to higher temperatures, due to the acceleration of the chemical reaction resulting in the curing and hardening of the adhesive binder. Accordingly, in many circumstances, it may be desirable to add heat to the manufacturing process, in order to reduce the amount of time required to produce a finished slab or panel. This is indicated in the fifth step 420 of Figure 7. The amount of heat used to cure and harden the poured slabs or panels may be adjusted according to the thickness of the slab or panel and the amount of time available for curing, up to the point at which further heat would damage the structural properties of the adhesive binder material. The precast panels 10 may be heated in an oven or other suitable closed structure capable of retaining heat. However, as noted further above, the poured in place slabs 100 may also be heated to accelerate the curing time, by using suitable heating means as discussed above. Either of the curing and hardening steps 400 (using ambient temperatures) or 420

(applying heat) may be used to provide a finally cured and hardened panel or slab, as desired. In summary, the present building materials comprising slabs 100 and panels 10 and 10a, will be seen to provide an attractive, durable, yet economical, means of providing floors and wall and ceiling panels for building structures. The present slabs 100 and panels 10 and 10a are particularly well suited for mild or tropical climates, where the porous nature of the cured materials allows a building structure constructed using such materials, to "breathe, " passing air and water vapor, as well as liquid water and other liquids, through the myriad interstitial passages of each of the panels 10 and 10a or slabs 100. Yet, the slabs and panels are formed of non-flammable materials and are rigid when cured, to meet most safety and building codes. The acoustic properties of the slabs 100 and panels 10, even without the addition of further acoustic material thereto, provide good noise attenuation as well, for use as exterior building panels. The mineral particulates (e. g., sand) and resin adhesive mix used in the formation of the present materials are non-toxic, non- polluting, and are environmentally benign when the adhesive material is cured, thus assuring that the materials formed therefrom are safe for use in virtually all environments.

As the slabs 100 and panels 10 and 10a are anticipated to be visible in most construction, they may be tinted or otherwise colored by providing a coloring agent which may be mixed with the granular material and adhesive binder used in the formation of the present slabs 100 and panels 10 and 10a, prior to the curing and hardening of the aggregate mix. The resulting slabs and panels in any of their embodiments may be used to form a rapidly and economically constructed structure, which will serve its users efficiently and attractively for quite some time. The depression or cavity which may be provided in embodiments of the present panel, e. g., the panel 10a of figure 4, allows various insulation means (soundproofing, temperature control, etc.) to be placed therein to improve the efficiency of the panel 10a. As the panels 10 and 10a and slabs 100 are anticipated to be visible in most construction, they may be tinted or otherwise colored by providing a coloring agent which may be mixed with the granular material and adhesive binder used in the formation of the present panels 10 and 10a, prior to the heating of the aggregate mix to cure and harden the adhesive material. The resulting panels in any of their embodiments may be used to form a rapidly and economically constructed structure, which will serve its users efficiently and attractively for quite some time.

It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.

Claims

1. A building material, comprising: a quantity of particulate mineral matter mixed with an adhesive binder to form a rigid aggregate when said adhesive binder is cured and hardens; and said rigid aggregate being porous and including a myriad of interstices therethrough for the passing of air and water vapor through said rigid aggregate and for the providing of acoustic properties to said rigid aggregate.

2. The building material according to claim 1, wherein said rigid aggregate is formed of non-flammable materials.

3. The building material according to claim 1, wherein said particulate mineral matter comprises quartz sand grains.

4. The building material according to claim 3 , wherein said sand grains are rough and irregular.

5. The building material according to claim 1, wherein said adhesive binder comprises a synthetic resin.

6. The building material according to claim 1 wherein said adhesive binder includes epoxy resin

7. The building material according to claim 1 wherein said adhesive binder includes polyester resin.

8. The building material according to claim 1, including a coloring agent mixed with said particulate mineral matter and adhesive binder.

9. The building material according to claim 1, wherein said rigid aggregate is formed as a wide and flat panel having a first surface and an opposite second surface.

10. The building material according to claim 9, wherein said second surface of said panel has a depression formed therein.

11. The building material according to claim 10, wherein said depression is substantially filled with an acoustic material.

12. The building material according to claim 11, wherein said acoustic material comprises a non-flammable material.

13. The building material component according to claim 1, wherein said rigid aggregate is formed of a mix by volume of approximately

10 percent adhesive binder and 90 percent particulate mineral matter.

14. The building material component according to claim 1, wherein said rigid aggregate is formed as a wide and flat panel having a first surface and an opposite second surface defining a thickness therebetween, with said thickness having a range between three and forty millimeters.

15. The building material component according to claim 1, wherein said rigid aggregate is formed as a wide and flat panel having a major lateral dimension with a range between one quarter of an inch and eight feet .

16. The building material component according to claim 1, wherein said rigid aggregate is formed as a large, continuous slab of material having a thickness with a range between three millimeters and fifty centimeters.

17. A method of forming a building material component, comprising the steps of:

(a) providing a first quantity of particulate mineral matter and a second quantity of adhesive binder;

(b) mixing the particulate mineral matter and the adhesive binder together; and

(c) curing and hardening the adhesive binder, thereby forming a rigid aggregate having a myriad of interstices therethrough for the passing of air and water vapor through the rigid aggregate .

18. The method of forming a building material component according to the method of claim 17, further including the step of forming the rigid aggregate of non-flammable materials.

19. The method of forming a building material component according to the method of claim 17, wherein the step of providing a first quantity of particulate mineral matter includes using quartz sand grains .

20. The method of forming a building material component according to the method of claim 19, wherein the step of using quartz sand grains includes using rough and irregular quartz sand grains.

21. The method of forming a building material component according to the method of claim 17, wherein the step of providing a second quantity of adhesive binder includes using an epoxy resin as the adhesive binder.

22. The method of forming a building material component according to the method of claim 17, wherein the step of providing a second quantity of adhesive binder includes using a polyester resin as the adhesive binder.

23. The method of forming a building material component according to the method of claim 17, further including the step of coloring the rigid aggregate by adding a coloring agent to the particulate mineral matter prior to mixing the particulate mineral and adhesive binder.

24. The method of forming a building material component according to the method of claim 17, further including the step of forming the rigid aggregate as a wide and flat panel having a first surface and an opposite second surface .

25. The method of forming a building material component according to the method of claim 24, further including the step of forming a depression in the second surface of the rigid aggregate.

26. The method of forming a building material component according to the method of claim 25, further including the step of filling the depression with an acoustic material.

27. The method of forming a building material component according to the method of claim 26, wherein the step of filling the depression with an acoustic material includes using a nonflammable material as the acoustic material.

28. The method of forming a building material component according to the method of claim 17, further including the step of forming the rigid aggregate as a wide and flat precast panel having a first surface and an opposite second surface defining a thickness therebetween, with the thickness having a range between three and forty millimeters.

29. The method of forming a building material component according to the method of claim 17, further including the step of forming the rigid aggregate as a wide and flat precast panel having a major lateral dimension with a range between one quarter of an inch and eight feet.

30. The method of forming a building material component according to the method of claim 17, further including the steps of:

(a) pouring the viscous adhesive binder into a form at a construction site; and (b) curing the material into a hardened continuous slab by exposing the material to ambient temperatures over a period of time ranging from thirty six hours to two weeks.

31. The method of forming a building material component according to the method of claim 30, further including the step of pouring the slab to provide a thickness with a range between three millimeters and fifty centimeters.

32. The method of forming a building material component according to the method of claim 17, including the step of curing and hardening the material by heating the material to a temperature above ambient .